News

University of Alberta joins Canada Makes

Canada Makes is pleased to announce the addition of the University of Alberta to its list of world-class Additive Manufacturing research institution partners. The University of Alberta is a Top 100 university in the world and one of seven Canadian university partners in the NSERC/CFI Holistic Innovation in Additive Manufacturing (HI-AM) Network.

“Canada Makes is very fortunate to have the University of Alberta as part of our network,” said Frank Defalco, Manager Canada Makes. “We look forward to working with this great institution in developing additive manufacturing capabilities in Alberta as well as all of Canada.”

The University of Alberta has a mission to discover, disseminate and apply new knowledge through teaching and learning, research and creative activity, community involvement, and partnerships. U of A gives a national and international voice to innovation in Alberta, taking a lead role in placing Canada at the global forefront.

The University of Alberta and Innotech Alberta are hosting a two-day workshop addressing Additive Manufacturing in Alberta. Be sure to register and be part of this important event and help Alberta become more innovative and competitive. Learn more here http://canadamakes.ca/additive-manufacturing-alberta-workshop/

About the University of Alberta
The University of Alberta is a public research university with more than 38,000 students from 148 countries located in Edmonton, Alberta, Canada. Founded in 1908 by Alexander Cameron Rutherford, the first premier of Alberta, and Henry Marshall Tory, its first president. It has 388 undergraduate programs, 500 graduate programs as well as 100+ institutes and centres. ualberta.ca

Canada Makes 3D Challenge 2018-19


Canada Makes is again offering its Pan-Canadian 3D Printing Design Challenge for postsecondary students enrolled in a Canadian college or university. Winners to be announced in the Spring of 2019.

Canada Makes 3D Challenge Trophy

Lisa Brock and Yanli Zou of the University of Waterloo are now part of the Canada Makes trophy’s history

Last year’s challenge was “Design solutions for a sustainable future” and is again this year. Five finalist from last year’s challenge each received $1,000 for their design. Learn more about the designs at Canada Makes announces finalists for its 3D Challenge.

The adoption of digital manufacturing technologies such as 3D printing requires new approaches to skills and training focused on building experiential and collaborative learning. To foster this objective, the Canada Makes 3D Challenge will challenge university/college teams to design a part and compete for a full one-year paid internship from a Burloak Technologies and cash prizes.

Theme: Design solutions for a sustainable future

Description: Additive manufacturing is empowering new ways to re-think design and fabrication through innovative materials, optimized structures and enhanced functionality. There is currently a drive to think about how our society is changing in the wake of population growth and sustainability concerns. Canada Makes invites student designers to participate in the 3D Design Competition with a focus on creating innovative tools or products that reduce our environmental footprint using additive manufacturing in tandem with conventional manufacturing approaches.

Such examples include (and are not limited to):

  • lightweight structures or new designs of automotive or aerospace components that reduce overall weight and fuel consumption
  • innovative components that optimize fuel or energy consumption
  • energy harvesting devices with innovative features
  • multi-purpose objects that simplify everyday life and reduce waste
  • wearable tools or objects that enhance mobility efficiency and reduce waste

Pre-Register here

Phase I – Students who wish to participate must pre-register by November 30, 2018 indicating their intent to submit a final design.

Phase II – Participants will submit a design based on the provided criteria. These designs will be analyzed and evaluated via simulation with the top finalists announced, recognized and awarded their cash prize. Deadline for submissions is February 22, 2019.

Phase III – The top five finalists will have their design fabricated and tested, and will be invited to either make a live or video presentation and have a chance at more prizes including a chance at a one-year paid internship at Burloak Technologies.

Registration Process

After Pre-registrations Student/Team (no more than 3 students per team) will submit the following by February 22, 2019:

  • Cover sheet
  • 150 word description/summary
  • STL files and source files from any CAD program
  • An image of the current product design (if applicable) and a detailed description of the changes
  • Business case (800 word):
  • Justification of the product redesign, value added as measured by reduced
  • Time to produce
  • Cost impact
  • Sustainability
  • Energy consumption or renewable energy generation
  • Reduced materials
  • Promoting green design
  • Participants should define the unmet need in society or explain the waste in current solutions
  • Precisely what is being proposed
  • Why it is am improvement over existing products

Judges will choose the top 5 finalists and Canada Makes will arrange to fabricate their designs to be showcased at a final event in the spring of 2019. The finalist/teams will receive a cash prize and a chance at a one-year paid internships at Burloak Technologies.

The Challenge will have clear winning criteria and be judged on the merit of their application.

Submitted designs will be evaluated via simulation, and the top five designs will be selected for fabrication and testing based on the required criteria. The winning entries will best satisfy all of the performance criteria.

Eligibility Rules and Submission Guidelines

Terms of Acceptance

Responsibility for Submission

Privacy

Contact: Frank Defalco frank.defalco@cme-mec.ca

Lambton College’s Bluewater Technology Access Centre joins Canada Makes

Canada Makes is pleased to announce Sarnia, Ontario based Lambton College’s Bluewater Technology Access Centre’s (BTAC) as it newest member. BTAC is Lambton College’s frontline for industry innovation and is a specialized research and development centre that works with Canadian businesses – especially SME’s – to advance their products, processes, and services.

“BTAC provides access to new technologies, state-of-the-art equipment, expertise and funding sources. Their main focus is on advanced manufacturing and 3D printing and Canada Makes looks forward to having them as part of our National network of advanced manufacturing experts,” said Frank Defalco Manager, Canada Makes.”

BTAC helps companies through applied research and development projects focusing on solving problems. BTAC offers technical services and object analysis and provides training related to new types of equipment and processes. Other areas of expertise include advanced material development, instrumentation, process control and optimization, renewable energy conversion, storage and management, bio-technology and more.

About Lambton College’s Bluewater Technology Access Centre
BTAC is a One-Stop-Innovation Hub that supports the manufacturing and fabrication industry, businesses and organizations with access to expertise – students, faculty and infrastructure at Lambton College. Emphasis is on product and process development and/or improvement. These collaborative projects between companies and Lambton College create an enriching student learning experience, train highly qualified personnel and support innovation within organizations. After 5 years of operation and success the Natural Sciences and Engineering Research Council (NSERC) has renewed BTAC’s funding until March 2023. https://www.lambtoncollege.ca/BTAC/

 

SLM Solutions joins Canada Makes

Canada Makes is pleased to announce SLM Solutions has joined its Additive Manufacturing (AM) network. SLM Solutions provides powder bed fusion machinery and applications development for metal prototypes and manufacturing production. It focuses on the development and distribution of innovative, production-oriented metal additive manufacturing systems.

“SLM Solutions was the first to offer overlapping multi-laser systems for the selective laser melting process and Canada Makes welcomes the addition of this proven innovator as its newest partner,” said Frank Defalco, Manager Canada Makes.

SLM Solutions is a leading provider of industrial selective laser melting equipment. With Canadian distribution partners, like Spark & Co and an AM technology center in Detroit, SLM Solutions partners with customers to aid in the development of projects and reduce the learning curve for success with metal additive manufacturing.

SLM Solutions takes a vested interest in your company’s long-term success with metal AM, providing support and knowledge-sharing that elevates use of the technology to the next level. SLM systems, available in multiple sizes, are utilized in a variety of industries around the world. Their open system architecture allows users to tailor their process and SLM Solutions’ extensive experience and technical know-how help drive innovative product developments and support customers’ competitive creativity.

About Spark & Co
Spark & Co works with Tier 1 and Tier 2 Aerospace firms to manufacture parts for major Aerospace manufacturers such as Boeing, Bombardier, Airbus, Embraer, and more. https://www.spark-co.com

Interview with NRC’s David Muir

Canada Makes is pleased to have had the chance for a one-on-one interview with David Muir of Canada’s National Research Council (NRC). David shares with us his vision and plans for the London NRC.

The NRC is the Government of Canada’s largest research organization supporting industrial innovation, the advancement of knowledge and technology development. For more than a hundred years, NRC has pushed the boundaries of science all the while working with industry to help shape Canada’s future.

Dr. David Muir NRC London

David Muir earned his B.Sc and Ph.D. in Chemistry from the University of Western Ontario, in London Canada, with his doctoral research focused in synthetic organic chemistry. He completed a postdoctoral fellowship with the University of Alberta in Edmonton, Canada in natural product chemistry.

David joined 3M Canada in London, Canada in 1996, gaining technical and management experience in Research and Development in several industrial sectors. He served as Integration Manager in the acquisition of a Canadian company, in which he held senior level management responsibilities in Operations, Finance, and R&D.  David was then appointed into business management roles in the Healthcare sector, including Food Safety and Infection Prevention Divisions.

Dr. Muir joined the National Research Council in July 2015 as Director of R+D for the London, Ontario facility within NRC’s Automotive and Surface Transportation portfolio.

Tells us about the NRC, particularly the London NRC that you head?

London NRC

The National Research Council of Canada is our national Research and Technology organization. NRC is over 100 years old, and has a very proud heritage of significant developments such as steam locomotives designed for the Canadian climate, Canola oil, the crash position indicator, electric wheelchair, and recently 100% biofuel filled flights. Our mandate is to support the Canadian economy through innovation in science and technology. NRC London, on the grounds of Western University, opened in 1997 primarily to support the manufacturing and construction industries. The construction activities across Canada were consolidated in Ottawa around 2010, and so our focus is manufacturing, particularly in the Automotive sector. We have a 75 000 sq ft facility, combined offices, labs, 2 automotive bays and a 10 ton crane high bay.

What should the new NRC “labs” be?

Our new labs will allow us to support and grow our research and development in Additive Manufacturing, Microfabrication, Specialty Coatings and Functional Surfaces. We will also be creating new space and capability for R+D in Mechatronics and Control Systems as well as Engineering Data Analytics. Finally, since we have had significant industry feedback regarding demonstration and integration of technology, we will be creating facilities that can enable whole vehicle and digital factory level scale.

The so-called “Factory of the Future,” tell us about the progression you have seen to get where you are now?

Dr. David Muir

When I arrived at NRC London 3 years ago, investment in our facility to support advanced manufacturing had just been announced. We polled industry quite exhaustively for their needs, and held workshops to validate our findings. This feedback told us to focus on applications for digital manufacturing and connected/autonomous vehicles. Within these applications, we heard very strong needs in key technological domains, as well as a facility that can integrate technology at a full vehicle or factory demonstration level. Additionally, we heard clearly that we need to create a facility that is collaborative in which private, public and academic sector can work together to solve pressing challenges. So with this feedback, we set out to renovate our facility, hire scientists and engineers and acquire equipment that incorporate these needs. I am pleased to report that this facility is now substantially complete and we are preparing for an opening in the fall.

How do you see the NRC’s place in helping companies adopt and use the applications and concepts of Industry 4.0.

First of all, our goal is to help companies de-risk implementation of new technology. I see several means by which we can do this – expertise to advise on technology, a demonstration facility to show new technology in use at a scaled-up level, a platform for industry to trial their own process before implementing, use cases for new applications of technology, and research into new areas. Industry for example has fed back that they have heard a lot about digital manufacturing or Industry 4.0, but they cannot visualize or understand how to implement. An additional benefit that clients can leverage at NRC London is access to the full breadth of the NRC. We are a relatively small facility, however, we can help clients access the >3000 employees of the NRC.

Will you focus on any particular advanced technologies? If yes what and why?

NRC London has created very strong and world recognized capabilities in additive manufacturing, microfabrication and surface functionalization. We will continue to develop in these areas as they continue to be of strong interest to industry. In addition, industry feedback has shown 2 major areas for focus, Mechatronics and Control Systems as well as Engineering Data Analytics.   Finally, integration of technology for connected/autonomous vehicles and digital manufacturing will be a skillset employing hard/software interoperability, autonomous systems, cybersecurity and communications.

Where do you see this initiative having its biggest impact?

We see impact to manufacturers of all size in Canada. Companies interested in new technology or adoption of technology related to digital manufacturing and/or connected/autonomous vehicles.

Thank you David.

 

 

Additive Manufacturing Alberta Workshop


InnoTech Alberta, in conjunction with Canada Makes and the University of Alberta, is hosting a two-day workshop addressing Additive Manufacturing in Alberta.

How do we work together to become more innovative and competitive?  What tools do we need to adopt?  What changes do we need to make?

The first day is a training course presented by AddWorks from GE Additive.  The full day course will discuss the concepts and tools necessary to adopt additive manufacturing.

The second day highlights a number of invited speakers and panelists to showcase their best practices in adoption of additive manufacturing.

This event is targeted towards designers, engineers, fabricators, innovators, and owners.

Dates:
Wednesday, October 10, 2018
Registration and continental breakfast – 8am
Course – 9am-4pm

Thursday, October 11, 2018
Registration and continental breakfast – 8am
Workshop – 8:45am-4pm
Reception, Trade Show, Poster Presentation – 4-5pm

Cost includes:  workshops and all meals (breakfast, lunch, reception and coffee breaks)

Location – Alberta Innovates/InnoTech Alberta, 250 Karl Clark Road, Edmonton, AB

Register https://am-alberta.eventbrite.ca

Innotech Alberta  

InnoTech Alberta, in conjunction with the University of Alberta and Canada Makes, is hosting a two-day workshop addressing Additive Manufacturing in Alberta.

  • How do we work together to become more innovative and competitive?
  • What tools do we need to adopt?
  • What changes do we need to make?

The first day is a training course presented by Addworks™ at GE Additive. The full day course will discuss the concepts and tools necessary to adopt additive manufacturing.

The second day highlights a number of invited speakers and panelists to showcase their best practices in adoption of additive manufacturing.

This event is targeted towards designers, engineers, fabricators, innovators, and company owners.

*Earlybird discounts are in effect until Sept. 15th.

*Ticket price includes continental breakfast and hot lunch (please contact the organizer if you have special dietary requirements)

Day 1: Learning Seminar – Wednesday, October 10 (9:00AM-4:00PM)

Breakfast and Registration start at 8:00am

Presented by: Valeria Proano Cadena, Lead Engineer, Addworks™ at GE Additive and Joe Hampshire, Product Strategy Leader, Addworks™ at GE Additive

Title

Best practices for your Additive Journey – Design, Process Selection, and Materials

Abstract

As organizations begin to adopt additive technology, they quickly realize that it takes different thinking, tools and processes to be successful in using additive in production-level manufacturing. In this workshop, Addworks™ at GE Additive will cover key concepts and best practices they use on a daily basis for its production of additive parts.

AddWorks is GE Additive’s engineering consulting team that helps companies with additive part development and production in the automotive, aviation and energy/power industries. Regardless of how simple or complex, AddWorks can help you navigate your additive journey and find a path most beneficial to your goals. GE Additive started their own additive journey over 4 years ago and is now the #1 additive user in the world.

The following outlines learning objectives for this workshop:

  1. Real-life use case examples of additive manufacturing
  2. Design best practices including requirements, conceptual design, process selection, producibility and FastWorks
  3. An overview of the material development process where machine parameters in combination with post processing drive the material properties and performance
  4. An overview of additive manufacturing processes and the various additive technologies
  5. An overview of the GE Additive innovation process used for the Additive Manufacturing
  6. Cost modeling considerations and methods for additive components.

Day 2: Workshop – Thursday, October 11, 2018 (8:45AM – 4:00PM)

Breakfast and Registration start at 8:00am

Join us after the Workshop for a reception, tradeshow, and poster presentations (starts at 4:00pm).

Keynote Speaker:

Disrupting the Disruption: How GE Additive is Pushing the Boundaries of AM, Joe Hampshire, Addworks™ at GE Additive

Invited Speakers:

  • Mark Ramsden, Director, Business Performance and Innovation, Worley Parsons
  • Ian Klassen, Director, Aerospace Sales and Business Development, Precision ADM
  • Dr. Dan Thoma, Director of Additive Network, University of Wisconsin
  • Dr. Mohsen Mohammadi, Director, Marine Additive Manufacturing Centre of Excellence, University of New Brunswick
  • Tharwat Fouad, President, Anubis 3D

Panel Discussions

Opportunities of Additive Manufacturing for the Energy Industry

Chair: Dr. Ehsan Toyserkani, University of Waterloo

  • Stefano Chiovelli, Syncrude Canada
  • Carl Weatherell, Canadian Mining Innovation Council
  • Philip Leung, Halliburton
  • Tyler Romanyk, Halliburton

Challenging the Status Quo in Alberta Manufacturing – a Small Business Perspective

Chair: Frank Delfaco, Canada Makes

  • Billy Rideout, Exergy
  • Darryl Short, Karma Machine
  • James Janeteas, Cimetrix
  • Kyle Hermenean, Machina Corp

Student Poster Presentation – Thursday, October 11

Students are invited to present their research using poster format. The best poster will be selected by an industry-academia-government committee and awarded a prize of $250.

Maximum size is 36” Tall x 48” wide.

Please contact Dr. Bogno (bogno@ualberta.ca) to submit your name, group, poster title/abstract, or for any poster related inquiries.

Students are required to submit a title and an abstract (max 200 words) of their poster. Deadline for submission is September 24.

Students must register for the Thursday event to submit a poster, although students are also welcome to register for the Wednesday event.

Posters should be submitted by Tuesday, October 9 at noon to Dr. Bogno.

______________________________________

For addtional event details please contact:

Dr. Tonya Wolfe, InnoTech Alberta

tonya.wolfe@innotechalberta.ca

Promation joins Canada Makes

Canada Makes is pleased to announce Promation as its newest partner to join our National Additive Manufacturing network. The Oakville, Ontario based Promation is now offering 3D printing solutions to go with its Engineering, Equipment and Tooling Solutions for the Automotive, Nuclear and Aerospace & Defense Industries.

Mark Zimny, Promation’s Founder and CEO said, “Promation is pleased to join Canada Makes.  The benefits that Advanced Manufacturing and Additive Manufacturing expertise can bring to Canadian industry and academia through Canada Makes will have a significant impact on our future.  We expect this to be a key part of our Accelerated Growth Strategy to double to size of Promation within the next 5 years.”

“Canada’s manufacturing sector is fortunate to have a company like Promation join Canada’s Additive Manufacturing supply chain. Promation’s proven capabilities and proficiency in project management, advanced automation technology, engineering and a developed manufacturing facility will be a great benefit to its partnering companies,” stated Frank Defalco, Manager Canada Makes.

Promation has partnered with University of Waterloo’s Multi-Scale Additive Manufacturing Lab to develop the next generation of metal additive manufacturing that will enable high-value applications at a higher quality and lower operating costs. They have also established a network of research centers, first-class AM partners and suppliers to deliver complete integrated solutions to their clients ranging from simple devices to integrated systems and production facilities custom-tailored to customer-specific requirements.

Promation’s work with the Multi-Scale Additive Manufacturing Lab focuses on the next generation of additive manufacturing processes. To this end, the lab explores novel processes and techniques to deliver advanced materials, innovative products, modeling and simulation tools, monitoring devices, closed-loop control systems, quality assurance algorithms and holistic in-situ and ex-situ characterization techniques.

About Promation
Founded in 1995, Promation,a privately owned Canadian Corporation, is a leading automation, robotic and tooling system manufacturer in Oakville, Ontario. Promation delivers custom equipment and turnkey systems to their global customers in three divisions; Nuclear, Automotive, and Aerospace & Defence. They customize best-in-class solutions, which are supported by a team of experienced PLC designers, engineering, manufacturing and quality professionals with industry expertise. www.promation.com

 

Canada Makes Additive Manufacturing Forum – Aerospace and Automotive Tooling

The CME Canada Makes Additive Manufacturing Forum of October 24, 2018 at the University of Waterloo will feature speakers from both the Aerospace and Automotive/tooling sectors who will discuss on how they improved their competitiveness through the adoption of additive manufacturing.

Join us and learn more about this emerging sector.

The Forum will feature two panels, “Aerospace using Additive Manufacturing” and “Conformal Cooling – Facts versus Myths Overcoming Obstacles.”

  • Panel 1 – Aerospace and Additive Manufacturing, moderator Mark Kirby
  • Panel 2 – Conformal Cooling – Facts versus Myths Overcoming Obstacles, moderator Ed Bernard

The forum will continue to deliver on the success of past events and offer ample opportunity for networking. The Canada Makes Scrum, introduced last year, will once again use the same format. Canada Makes partners will circle the room with tables and banners and take part in a great opportunity to talk face-to-face with experts in additive.

Canada Makes continues offering insight and expertise for Canada’s industry leaders with the mission of helping companies understand how they might use additive manufacturing as part of their process. The forum will show how additive is a key component of Industry 4.0, implementation.

Time: 8 a.m. – 4:30 p.m.
Location: Federation Hall (Building #35) University of Waterloo
200 University Ave W, Waterloo, ON
Cost:
$100 CME Members/Canada Makes Partners
$150 CME / Canada Makes Non-Members

Register

The Master of Ceremony is David Saint John Director of Innovation and Advanced Manufacturing Linamar.

View the list and bios of speakers here

Agenda

Time Topic Speaker
8:00 – 9:00 a.m. Registration and Networking Coffee
9:00 – 9:10 a.m. Welcome Remarks Peter Adams, CEO & President Burloak Technologies
9:10 – 9:45 a.m. Laser Beam Melting drives efficiency of tooling applications Mathias Gebauer, Fraunhofer Group Manager for AM applications
9:45 – 10:15 a.m. How Additive Manufacturing has shaped the automotive sector and is driving it into the future Cassidy Silbernagel, two time winner of the Additive World Design for Additive Manufacturing Challenge
10:15 – 10:40 a.m. Networking Break
10:40 – 11:40 a.m. Panel Conformal Cooling – Facts vs Myths and Overcoming Obstacles Moderator Ed Bernard

Panellists: Wes Byleveld, Director, Additive Manufacturing Exco Engineering

Annette Langhammer, Director of Advanced Engineering NMC Dynaplas

Tom Houle, Director Lumex, NA at Matsuura Machinery USA, Inc.

11:40 – 12:00 p.m. The Efficacy of Computed Tomography for Additively Manufactured Parts Dylan Yazbeck, Lab Supervisor Jesse Garant Metrology Center
12:00 -1:15 p.m. Networking Lunch
1:15 – 1:45 p.m. Aerospace and Additive Manufacturing applications Peter Adams, CEO & President Burloak Technologies
1:45 – 2:45 p.m. Additive Manufacturing in Aerospace. Moderator Mark Kirby

Panellists: Roger Eybel, Materials and Processes Group Leader/Safran Expert
Safran Landing Systems

Mathieu Fagnan, Enterprise Manager, Additive Manufacturing Technologies Pratt & Whitney Canada

Steve Slusher, Executive, AddWorks Manufacturing Development Leader (GE)

2:45 – 3:00 p.m. Presentation: Survey on Green aerospace practices in Canada François Charron-Doucet, Director of Quality Control and Scientific Director at Groupe AGÉCO
3:00 – 3:15 p.m. Market update on Medical AM Martin Petrak, President & CEO Precision ADM
3:15 – 3:30 p.m. Update on the Medical 3D Printing Centre in Québec Olivier Marcotte, Agent de recherche et développement, CRIQ
3:30 p.m. 5:00 p.m. Reception brought to you by CRIQ Networking Reception – Wine, beer and soft drinks.

We thank Burloak Technologies as our major corporate sponsor.The following companies will be sharing their expertise at the Canada Makes Scrum.

BDO

MAP UNIVERSITY OF WATERLOO LOCATION OF CANADA MAKES FORUM

 

Additive Manufacturing 101: How to (re)design your parts for Additive Manufacturing

(Image: 3D Hubs)

Redesigned concept of a carburetor (Image: Cassidy Silbernagel)

  Mechanical Design Engineer and Additive Manufacturing Ph.D. student

This is the final article in a series of original articles that will help you understand the origins of the technology that is commonly called 3D printing. First an introduction, followed by the seven main technologies categories (binder jetting, directed energy deposition, material extrusion, material jetting, powder bed fusion, sheet lamination, vat photopolymerization) and now a design philosophy for additive manufacturing.

Design for Additive Manufacturing

All of these following principles differ greatly for each technology category. Some are not a concern, others are a major concern. Before you design for AM, you need to know which process you are designing for, and if possible, what machine it will be built upon. Each machine and even different materials differ on some of these aspects.
https://www.linkedin.com/pulse/design-metal-am-beginners-guide-marc-saunders/

Supports / Overhangs

Each technology deals with this differently. Generally, there is a critical angle (typically 45 degrees) that allows no support to be needed such as in the letter Y. Some need supports for all bridges of a certain length such as the middle of a capital H. Others need supports for overhangs such as at the ends of a capital T. How supports are designed or generated and removed needs to be thought of in the design process. By changing or re-orientating the design, you can minimise the need for supports, and change how the supports are removed.

Orientation

Two factors come into play for orientation. First is material properties can differ depending on the direction they are built. This shows some test bars I printed to test how build orientation affects the electrical resistivity of a metal alloy. Strength can differ depending on build orientation so if you have a part that needs to have a certain strength in a certain direction, you will need to know how the orientation affects the strength of the part.


Images: Marc Saunders

The second is that printed features can come out looking differently depending on orientation. If you have a circle you want to print and have it come out circular, you will need to orient the part so that the circle is in the XY plane and not chopped up by the layers.

Minimum feature size / Resolution

This greatly depends on the process you use, and especially the machine you use. Just because two machines from different manufacturers use the same technology, they may not have the same feature specifications. There are also many factors that play into minimum features, and each is different. Here you can see some of the minimum sizes for a typical SLS process in Nylon. This is where you need to find out the machine and material specific specifications if you want to be designing features in the submillimeter range.

Post-Processing


There are many different ways post-processing can affect how you design. If the process relies on supports, they will need to be removed manually, or potentially semi-automatically. If attached to a build plate, the parts will need to be removed. If there is excess powder or liquid trapped, it will need to be removed. If you want uniform or enhanced material properties, a heat treatment or post infusing of a second material may be needed. If you have critical surfaces that assemble, post machining will be required including custom part holding jigs or fixtures. All of these need to be taken into consideration when designing in order to gain the greatest benefits from AM.

Four ways to (re)design parts

Method 1: Send directly for AM

Method 2: Modify for AM

Method 3: Combine and redesign for AM

Method 4: Rethink and redesign for AM

Method 1: Send directly for AM

The first and easiest is to simply take an existing design and without modification create it using AM technology. This is advantageous when the single part is excessively complex making it difficult to produce using traditional methods or made from materials that are expensive where minimal waste is desirable. This can also be desirable when the lead times for a part are excessively long or if the part is no longer manufactured.

Advantages

  • Easiest
  • Less material wastage
  • Direct single part replacement
  • Potential faster lead times
  • Allows easier manufacture of complex design

Disadvantages

  • Narrow scope of use
  • Limited potential gains

Method 2: Modify for AM

The second is to redesign the single part to either improve performance and/or to make the part better suited for AM.

Advantages

  • Improve performance
  • Decrease weight
  • Improve printability
  • Direct single part replacement
  • Less material wastage

Disadvantages

  • Requires same assembly methods and parts

Method 3: Combine and redesign for AM

The third is to combine multiple parts to aid in part reduction, reduce assembly costs, and enhance performance.

Before 3D printing, this fuel nozzle had 20 different pieces. Now, just one part, the nozzle is 25% lighter and five times more durable.

Advantages

  • Allows reduction of parts
  • Reduce assembly
  • Potentially less risk than a complete redesign of overall machine/assembly

Disadvantages

  • Requires more design time
  • Requires testing and validation

Method 4: Modify for AM

The fourth is to completely rethink the assembly and redesign according to basic first principles and design requirements. While this complete redesign can yield the greatest results, it takes the most time and effort to achieve.

 

Image: Optisys LLCThe test project involved a complete redesign of a high-bandwidth, directional tracking antenna array for aircraft (known as a Ka-band 4×4 monopulse array).

Reduce part count reduction from 100 discrete pieces to a one-piece device.

  • Cut weight by over 95%.
  • Reduce lead time 11 to two months. (eight months of development, three to six more of build time)
  • Reduce production costs by 20%.
  • Eliminate 75% of non-recurring costs.

Advantages

  • Allows greatest performance increases
  • Eliminate parts and assembly
  • Reduce weight, cost, lead time

Disadvantages

  • Most amount of design effort

Tekna receives $21.1 million investment from the Governments of Canada and Quebec

Canada Makes applauds the announced investment of  $21.1 million to help scale up TEKNA and create 170 new jobs as well as promote Canadian innovation.

Today, the Honourable Navdeep Bains, Minister of Innovation, Science and Economic Development, announced that the federal government will invest up to $21.1 million in advanced manufacturing company TEKNA Plasma Systems Inc. Minister Bains was joined by the Honourable Marie-Claude Bibeau, Minister of International Development and La Francophonie and Member of Parliament for Compton–Stanstead. Luc Fortin, Member for Sherbrooke, Minister of Families and Minister responsible for the Estrie region—on behalf of Dominique Anglade, Deputy Premier of Quebec, Minister of Economy, Science and Innovation, and Minister responsible for the Digital Strategy, and François Blais, Minister of Employment and Social Solidarity—announced a $9.4-million investment from the Government of Quebec. The total value of the project is up to $128.4 million.

“Quebec is a leader in advanced manufacturing. The sector will employ close to 1.7 million Canadians and contribute $183 billion, or 10 percent, to Canada’s GDP in 2018. Today’s investment will create 170 jobs in Sherbrooke and will help TEKNA scale up to reach new markets and compete globally. It is investments like this one that will position Canada as a global innovation leader today and tomorrow.” 
– The Honourable Navdeep Bains, Minister of Innovation, Science and Economic Development.

“By creating products that didn’t even exist yesterday, TEKNA is contributing to the manufacturing revolution brought on by 3D printing and Industry 4.0. We are writing tomorrow’s history today. This investment project, though unprecedented, builds on 28 years of engagement with excellence and proves strategic for the company’s development, growth and prosperity. We are extremely proud that our shareholder Arendals Fossekompani ASA supports the choice of Sherbrooke, the city where TEKNA was founded, as the place to carry out this promising plan.”
– Luc Dionne, Chief Executive Officer, TEKNA Plasma Systems Inc.

This investment in advanced manufacturing will help create 170 jobs in Sherbrooke, will help attract foreign direct investment, and will help TEKNA produce innovative metallic powders used in additive manufacturing and electronic products. Additive manufacturing, also known as 3D printing, allows for the design of complex metal parts that are lighter and more efficient and environmentally friendly than conventionally manufactured parts.

TEKNA’s project will help the company increase its total manufacturing production capacity and footprint in Sherbrooke and will advance next-generation manufacturing capabilities in Canada. It will also increase R&D, stimulate collaboration with Canadian post-secondary institutions, and help strengthen the Montréal–Sherbrooke advanced manufacturing cluster and supply chain.

About TEKNA Plasma Systems
TEKNA, a subsidiary of Arendal Fossekompani ASA (AFK: NO), has been conducting manufacturing of industrial plasma systems and metal powders for more than 25 years, based on their strong R&D leadership. Today, TEKNA (headquartered in Canada) is a world-renowned actor for the quality of its products and its ability to respond quickly to the growing demands of its customers.